Note: Descriptions are shown in the official language in which they were submitted.
CA 2910349 2017-03-09
BRAIDED UPPER WITH OVERLAYS
FOR ARTICLE OF FOOTWEAR
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Patent
Application 61/839,097, filed June 25, 2013, and titled "Article of Footwear
with
Braided Upper" (Attorney Docket No. 51-3210) and referred to throughout the
detailed description as the "Braided Upper" application. This application is
also
related to co-pending U.S. Patent Application 14/163,392, filed January 24,
2014,
and also titled "Article of Footwear with Braided Upper" (Attorney Docket No.
51-3642).
BACKGROUND
[0002] The present embodiments relate to articles of footwear and in
particular to uppers for articles of footwear.
[0003] Athletic shoes often have two major components, an upper that
provides the enclosure for receiving the foot, and a sole secured to the
upper. The
upper may be adjustable using laces, hook-and-loop fasteners or other devices
to
secure the shoe properly to the foot. The sole has the primary contact with
the
playing surface. The sole may be designed to absorb the shock as the shoe
contacts the ground or other surfaces. The upper may be designed to provide
the
appropriate type of protection to the foot and to maximize the wearer's
comfort.
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SUMMARY
[0004] In one aspect, an article of footwear includes an upper and a
sole
system, where the upper made of a braided structure and an overlay portion.
The
overlay portion is bonded to the braided structure the overlay portion is less
resistant to stretching than the braided structure,
[0005] In another aspect, an article of footwear includes an upper and a
sole system, the upper being further associated with a lacing member. The
upper
is made of a braided structure and an overlay portion and the overlay portion
includes a plurality of eyelets for receiving the lacing member.
[0006] hi another aspect, a method of making an article of footwear
includes forming a braided structure with an interior cavity, cutting an
opening into
the braided structure, thereby creating an opening in the braided structure
and an
edge associated with the opening and bonding an overlay portion to the edge,
where the overlay portion includes a plurality of eyelets. The method also
includes
inserting a lace through the eyelets and associating a sole system with the
braided
structure to form the article of footwear.
[0007] Other systems, methods, features and advantages of the
embodiments will be, or will become, apparent to one of ordinary skill in the
art
upon examination of the following figures and de.tailed description. It is
intended
that all such additional systems, methods, features and advantages be included
within this description and this summary, be within the scope of the
embodiments,
and be protected by the following claims.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The embodiments can be better understood with reference to the
following drawings and description. The components in the figures are not
necessarily to scale, emphasis instead being placed upon illustrating the
principles
of the embodiments. Moreover, in the figures, like reference numerals
designate
corresponding parts throughout the different views,
[0009] FIG. 1 is a schematic isometric view of an embodiment of an
article of footwear including a braided upper with overlays;
[0010] FIG, 2 is an exploded isometric view of the article of footwear
of
FIG. 1;
[0011] FIG. 3 is a schematic isometric view of the article of footwear
of
FIG. 1, including an enlarged view of strands disposed against the overlay;
[0012] FIG, 4 is a schematic isometric view of another embodiment of an
arrangement of strands bonded to an overlay;
[0013] FIG. 5 is a schematic isometric view of the article of footwear
of
FIG. 1, including an enlarged cross-sectional view of an eyelet of the
overlay;
[0014] FIG. 6 is a schematic enlarged view of an embodiment of an
overlay including eyelets, in which each eyelet is partially encircled by a
strand of
a braided upper;
[0015] FIG. 7 is a schematic enlarged view of another embodiment of an
overlay including eyelets, in which strands of a braided upper do not encircle
each
eyelet;
[0016] FIG. 8 is a schematic rear isometric view of an embodiment of an
article of footwear including a braided upper with overlays;
[0017] FIG. 9 is a schematic exploded isometric view of an embodiment
of an article of footwear including a braided upper with multiple distinct
overlays;
[0018] FIG, 10 is a schematic side view of the article of footwear of
FIG.
9;
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[0019] FIG. 11 is a schematic top view of the article of footwear of
FIG.
9;
[0020] FIG. 12 is a schematic isometric view of an embodiment of an
article of footwear with two different braided regions and overlays covering
the
braided regions;
[0021] FIG. 13 is a schematic isometric view of the article of footwear
of
FIG. 12, in which a portion of the braided upper and an overlay are seen in
cross-
section;
[0022] FIG. 14 is a side schematic view of an embodiment of a pre-cut
braided structure shaped as an upper for an article of footwear;
[0023] FIG. 15 is a schematic view of a step of cutting the braided
structure of FIG. 14 in order to form an opening in the upper, according to an
exemplary process;
[0024] FIG. 16 is an isometric view of a step of joining an overlay to
the
upper of FIG. 15, according to an exemplary process;
[0025] FIG. 17 is an isometric view of an embodiment of a finished
article of footwear constructed using the exemplary process of FIGS. '14-16;
[0026] FIG. 18 is an isometric view of an embodiment of a braided upper
with an overlay on a lower surface being associated with a sole member; and
[0027] FIG. 19 is an isometric view of the braided upper of FIG. 18
joined with the sole member.
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DETAILED DESCRIPTION
[0028] FIG. 1 is an isometric view of an embodiment of an article of
footwear 100, also referred to simply as article 100. Article 100 may be
configured
for use with various kinds of footwear including, but not limited to: hiking
boots,
soccer shoes, football shoes, sneakers, running shoes, cross-training shoes,
rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes.
Moreover, in some embodiments article 100 may be configured for use with
various kinds of non-sports related footwear, including, but not limited to:
slippers,
sandals, high heeled footwear, loafers as well as any other kinds of footwear,
apparel and/or sporting equipment (e.g., gloves, helmets, etc.).
[0029] In some embodiments, article of footwear 100 may include upper
102 and sole system 110. Sole system 110 is secured to upper 102 and extends
between the foot and the ground when article 100 is worn. In different
embodiments, sole system 110 may include different components. For example,
sole system 110 may include an outsole, a rnidsole, and/or an insole. In some
cases, one or more of these components may be optional.
[0030] Sole system 110 may provide one or more functions for article
100. For example, in some embodiments, sole system 110 may be configured to
provide traction for article 100. In addition to providing traction, sole
system 110
may attenuate ground reaction forces when compressed between the foot and the
ground during walking, running or other ambulatory activities. The
configuration of
sole system 110 may vary significantly in different embodiments to include a
variety of conventional or non-conventional structures. In some cases, the
configuration of sole system 110 can be selected according to one or more
types
of ground surfaces on which sole system 110 may be used. Examples of ground
surfaces include, but are not limited to: natural turf, synthetic turf, dirt,
as well as
other surfaces.
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[0031] Generally, upper 102 may be any type of upper. In particular,
upper 102 may have any design, shape, size and/or color. For example, in
embodiments where article 100 is a basketball shoe, upper 102 could be a high
top upper that is shaped to provide high support on an ankle. In embodiments
where article 100 is a running shoe, upper 102 could be a low top upper.
[0032] Referring to FIG. 1, for purposes of reference, components of
article 100, such as upper 102, may be divided into forefoot portion 10,
rnidfoot
portion 12 and heel portion 14. Forefoot portion 10 may be generally
associated
with the toes and joints connecting the metatarsals with the phalanges.
Midfoot
portion 12 may be generally associated with the arch of a foot. Likewise, heel
portion 14 may be generally associated with the heel of a foot, including the
calcaneus bone. In addition, upper 102 may include lateral side 16 and medial
side 18. In particular, lateral side 16 and medial side 18 may be opposing
sides of
article 100. Furthermore, both lateral side 16 and medial side 18 may extend
through forefoot portion 10, rnidfoot portion 12 and heel portion 14,
[0033] It will be understood that forefoot portion 10, midfoot portion
12
and heel portion 14 are only intended for purposes of description and are not
intended to demarcate precise regions of upper 102. Likewise, lateral side 16
and
medial side 18 are intended to represent generally two sides of upper 102,
rather
than precisely demarcating upper 102 into two halves.
[0034] For consistency and convenience, directional adjectives are
employed throughout this detailed description corresponding to the illustrated
embodiments. The term "longitudinal' as used throughout this detailed
description
and in the claims refers to a direction extending a length of a component. For
example, the longitudinal direction of upper 102 may extend from forefoot
portion
to heel portion 14 of upper 102. Also, the term "lateral" as used throughout
this
detailed description and in the claims refers to a direction extending along a
width
of a component. For example, the lateral direction of upper 102 may extend
between medial side 18 and lateral side 16 of upper 102. Additionally, the
term
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"vertical" as used throughout this detailed description and in the claims
refers to a
direction that is perpendicular to both the longitudinal and lateral
directions.
[0035] In addition, the term "proximal" refers to a portion of a
footwear
component that is closer to a portion of a foot when an article of footwear is
worn.
Likewise, the term proximal direction refers to a direction oriented towards a
foot
when an article is word. The term "distal" refers to a portion of a footwear
component that is further from a portion of a foot when an article of footwear
is
worn. The distal direction refers to a direction oriented away from a foot
when an
article is worn.
[0036] In some embodiments, upper 102 may be comprised of a braided
structure, such as a braided fabric or other braided structure. Braided
structures
can be formed by intertwining three or more strands of yarn, filaments or
other
fibers to form the structure. As an example, upper 102 as seen in FIG. 1 is
formed
from a plurality of strands 130 that are braided together to form a shape that
is
globally similar to the shape of a foot.
[0037] Braiding can be used to form three-dimensional structures, by
braiding strands of yarn over a form or a last. Strands of the braided
structure,
such as plurality of strands 130 of the exemplary embodiment, can be
fabricated
from fibers such as nylon, carbon, polyurethane, polyester, cotton, aramid
(e.g.,
Kevlar0), polyethylene or polypropylene. These strands can be braided to form
three-dimensional structures for a wide variety of applications.
[0038] Braided structures may be fabricated manually, or may be
manufactured using automated braiding machinery, such as the machinery
disclosed in U.S. Patents Nos. 7,252,028; 8,261,648; 5,361,674; 5,398,586; and
4,275,638. Such three-dimensional braided structures may also be manufactured
to a specific design by, for example, TEF Braids, Warrensburg, N.Y or A&P
Technology, Cincinnati, Ohio.
[0039] By using braiding, uppers for articles of footwear may be
engineered with specific features tailored to a particular athletic or
recreational
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activity. Braided uppers can be very light while conforming closely and
comfortably to the wearer's feet. In some embodiments, the fit of the upper
may
be adjusted to provide the specific degree of tension or tightness the wearer
may
prefer. Braided uppers are characterized by close containment over the
wearer's
foot. In some embodiments, the braided fabric may wrap all the way around the
footwear, as shown in the figures. Such a structure has tensional integrity or
"tensegrity," since the wearer's foot is in compression, while the braided
strands
are in tension around the wearer's foot.
[0040] Some embodiments may include braided uppers that extend
beneath the foot, thereby providing 360 degree coverage at some regions of the
foot. However, other embodiments need not include uppers that extend beneath
the foot. In other embodiments, for example, a braided upper could have a
lower
periphery joined with a sole structure andior sock liner.
[0041] FIG. 2 illustrates an exploded isometric view of an embodiment of
article 100, including upper 102 which is comprised of a braided structure.
Referring to FIGS. 1-2, upper 102 is seen to have an opening 120 that may
receive a foot. Additionally, upper 102 has a fastening region 124. Fastening
region 124 may further include a fastening gap 125 that separates a lateral
fastening edge 126 from a medial fastening edge 127 (see FIG. 2).
[0042] Fastening region 124 may be further associated with that a
fastening member 160. In the exemplary embodiment, fastening member 160
may be a lace. In other embodiments, however, fastening member 160 could be
any other kind of fastener including but not limited to, straps, snaps,
buttons,
zippers, hook and loop fasteners (e.g., Velcro), as well as other kinds of
fasteners.
[0043] Embodiments utilizing braided uppers can include provisions to
help provide additional structure to the upper. In some embodiments, for
example,
an article may include one or more additional material portions that are
bonded or
otherwise attached to specific portions of the braided upper in order to
enhance
various characteristics of the upper. For example, these material portions may
be
used to increase strength and durability, provide stretch resistance at
certain
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locations of the upper and factate the joining of other components with the
braided structure.
[0044] Throughout the detailed description and in the claims, the term
"overlay portion", or simply overlay, refers to any portion of material that
is
attached to a surface of a braided structure, such as a braided upper. In some
embodiments, an overlay portion is comprised of a distinct material from the
strands of the braided structure. Moreover, in some embodiments, an overlay
portion may have substantially different material characteristics from the
strands of
the braided structure. In an exemplary embodiment, an overlay portion may
resist
stretching in comparison to a corresponding portion of a braided structure.
[0045] Generally, an overlay portion may be formed of any material.
Exemplary materials include, but are not limited to: fabrics (including woven
and
non-woven fabrics), leathers (including natural and synthetic leathers),
polymer
materials, as well as other kinds of materials. In one embodiment, one or more
overlay portions may be made of thermoplastic polyurethane (TPU).
[0046] In an exemplary embodiment, article 100 may be associated with
overlay component 140. Overlay component 140 may be further comprised of
several different overlay portions, including a first overlay portion 150, a
second
overlay portion 152 and a third overlay portion 154. Each overlay portion may
be
provided at a specific location on upper. For example, first overlay portion
150
may be associated with fastening region 124 of upper 102. Likewise, second
overlay portion 152 may be associated with opening 120. Finally, third overlay
portion 154 may be associated with heel portion 14 as well as portions of both
lateral side 16 and medial side 18 of upper 102.
[0047] Referring now to FIG. 2, in some embodiments, first overlay
portion 150 extends along the edges of fastening region 124. In particular,
first
overlay portion 150 includes a first section 181 that is associated with
lateral
fastening edge 126 of fastening region 124. Also, first overlay portion 150
includes a second section 182 that is associated with medial fastening edge
127 of
fastening region 124. In some embodiments, an intermediate section 183 runs
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along a forward most edge 129 of fastening region 124 and joins first section
181
and second section 182 of first overlay portion 150.
[0048] V`Vith this configuration, first overlay portion 150 may form, or
form
part of, the lateral and medial eyestays for upper 102. In particular, first
overlay
portion 150 may facilitate the attachment of upper 102 with fastening member
160.
As discussed in further detail below, the use of overlay portions along the
edges of
faste,ning region 1.24 may help to more evenly distribute the tensioning
forces
applied by fastening member 160 to upper 102.
[0049] In at least some embodiments, first overlay portion 150 may help
finish the braided structure of upper 102 along lateral fastening edge 126,
medial
fastening edge 127 and forward most edge 129 of fastening region 124.
Specifically, in embodiments where the strands of the braided structure may be
open at any of lateral fastening edge 126, medial fastening edge 127 or
forward
most edge 129, first overlay portion 150 may help to bond, fuse or otherwise
hold
the ends of the strands in place in order to prevent unraveling of the strands
along
these edges,
[0050] In some embodiments, second overlay portion 152 extends along
the edges of opening 120. In particular, second overlay portion 152 is
associated
with opening edge 195. In some embodiments, moreover, second overlay portion
152 is substantially continuous with first overlay portion 150, such that all
of the
edges of upper 102 associated with opening 120 and/or the opening at fastening
region 124 are covered by first overlay portion 150 or second overlay portion
152.
[0051] This arrangement helps to finish opening edge 195 by bonding
any open strands to second overlay portion 152. In addition, second overlay
portion 15.2 may help reinforce opening 120, so that the braided structure in
the
vicinity of opening 120 may not be overly stretched. Such reinforcement may be
especially useful at opening 120, since opening 120 may undergo a great deal
of
pulling and other stress as a user inserts and/or removes his or her foot,
[0052] In some embodiments, third overlay portion 154 may include a
first section 171 that extends along lateral side 16 and a second section 172
that
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extends along medial side 18 of upper 102. Additionally, a third section 173
of
third overlay portion 154 may extend beneath (e.g., on a lower side of) upper
102
at he& portion 14. In some embodiments, third section 173 joins first section
171
and second section 172 so that third overlay portion 154 wraps continuously
around the sides and bottom of upper 102.
[0053] In some embodiments, first section 171 of third overlay portion
154 extends from, and is continuously formed with, first section 181 of first
overlay
portion 150. Additionally, in some embodiments, second section 172 of third
overlay portion 154 extends from, and is continuously formed with, second
section
182 of first overlay portion 150. Because third overlay portion 154 may act to
reduce stretching along its length, this configuration may help increase
support
under the heel by resisting stretching of the upper between first overlay
portion
150 (at the top of the foot) and the lower side 199 (see FIG. 8) of heel
portion 14.
[0054] FIG. 3 illustrates an enlarged view of a portion of article 100
where some strands may be bonded to a second overlay portion 152. Referring to
FIG. 3, some strands 304 may be disposed against inner surface 302 second
overlay portion 152. In this exemplary embodiment, strands 304 may form part
of
a closed woven edge 305 of upper 102 that lacks any loose or free ends of
strands.
In this case, strands 304 may be bonded to second overlay portion 152 to
reinforce the continuously woven section of the braided structure.
[0055] In an alternative embodiment, shown in FIG. 4, some strands 470
may be configured with loose or free ends 472. In this configuration, open
ends
472 may be secured to overlay portion 452 in order to keep strands 470 in
place
arid help prevent strands 470 from loosening or unraveling. Thus it can be
seen
that in some embodiments, an overlay portion may be used to retain the loose
or
free ends associated with the edge of a braided structure. Such an arrangement
may provide a means of finishing cut edges of the braided structure, or any
edges
that include loose or free ends that might unravel.
[0056] The arrangement described here provides an overlay portion that
may act to reinforce the edge of the braided structure at opening 120. This
may
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help reduce stretching of upper 102 at opening 120, in order to preserve the
structural integrity of upper 102. In addition, second overlay portion 152 may
help
secure any loose or open ends of the braided structure to prevent fraying of
the
ends and/or unraveling of the braided structure.
[0057] Various processes for bonding an overlay portion to a braided
structure, such as a braided upper, are discussed in further detail below.
Exemplary materials used for bonding can include any known adhesives, melts,
resins or other bonding agents.
[0058] FIG. 5 illustrates an isometric view of article 100, including an
enlarged schematic cross-sectional view of a portion of first overlay portion
150
and fastening member 160. Referring to FIG, 5, first overlay portion 150
includes
a plurality of eyelets 400. Specifically, plurality of eyelets 400, including
eyelet 402
shown in the enlarged cross-section, are openings in first overlay portion 150
that
are configured to receive portions of fastening member 160,
[0059] In contrast to an alternative embodiment where strands of upper
102 may directly secure portions of a fastening member, the exemplary
embodiment is configured so that strands of upper 102 are indirectly secured
to
fastening member 160 via eyelets in first overlay portion 400. Specifically,
strands
410 are seen to be secured directly to first overlay portion 150, while
fastening
member 160 is secured through plurality of eyelets 400 in first overlay
portion 150.
This configuration may distribute forces imparted by fastening member 160 more
evenly across the braided structure of upper 102. This may prevent fastening
member 160 from tugging too much on a particular strand, for example, thereby
facilitating better comfort and fit of article 100 on a foot,
[0060] FIGS. 6 and 7 illustrate two possible configurations for strands
in
the vicinity of eyelets on an overlay portion. Referring first to FIG. 6, in
some
embodiments, one or more strands may extend around an eyelet, thereby acting
to reinforce the eyelet. For example, in FIG, 6, first strand 512 and second
strand
514 wrap around first eyelet 502 and second eyelet 504, respectively, This may
have the effect of reinforcing first eyelet 502 and second eyelet 504, as well
as
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providing a more direct transfer of tension between fastening member 160 and
the
braided strands of upper 102.
[0061] Referring to an alternative embodiment shown in FIG. 7, first
eyelet 502 and second eyelet 504 are not surrounded by any strands of the
upper.
In particular, it may be seen that strands 610 are bonded to first overlay
portion
150 without encircling first eyelet 502 and second eyelet 504. Of course, in
still
other embodiments, some eyelets may be surrounded or reinforced by strands
while other eyelets may not be surrounded or reinforced.
[0062] FIG. 8 illustrates a rear isometric view of upper 102, in which
strands 130 of upper 102 are shown in phantom. Referring to FIG. 7, third
overlay
component 156 is seen to wrap underneath a bottom side 199 of upper 102 at
heel portion 14. In some cases, this configuration allows third overlay
portion 156
to cradle the heel of the foot. Thus, this arrangement may provide further
support
for the heel of the foot when article 100 is worn by reducing stretching
through
heel portion 14,
[0063] In some embodiments, multiple distinct overlay components may
be used. In some embodiments, distinct overlay components may be configured
to intersect or overlap at predetermined portions of an upper. Such
configurations
of overlapping overlay components may provide a means for enhancing strength
and stretch resistance over large portions of an upper, including, possibly,
the
entirety of the upper.
[0064] FIGS. 9-11 illustrate an embodiment of an article of footwear
800,
comprising an upper 80.2 and a sole structure 805 (shown in FIG. 10 only),
Referring first to FIG. 9, upper 802 is comprised of a braided structure that
is
braided from a plurality of strands 830. In addition, multiple overlay
components
are associated with upper 802, including a first overlay component 810, a
second
overlay component 812, a third overlay component 814 and a fourth overlay
component 816.
[0065] In the exemplary embodiment, each overlay component is
associated with a particular portion of upper 802. For example, first overlay
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component 810 is associated with the edges 870 of opening 860 and fastening
region 862. Thus, in some cases, first overlay component 810 may be used to
finish plurality of strands 830 along edges 870. Additionally, first overlay
component 810 may provide stretch resistance in the vicinity of opening 860.
[0066] Second overlay component 812 is associated with forward toe
portion 868 of upper 802. In some embodiments, second overlay component 812
may help improve stretch resistance at forward toe portion 868. Additionally,
in
some embodiments, second overlay component 812 may provide a covering for
forward toe portion 868. In particular, the presence of second overlay
component
812 may help prevent debris from entering upper 802 through forward toe
portion
868.
[0067] Third overlay component 814 may be associated with a forefoot
portion 811 of upper 802. In some embodiments, third overlay component 814
may be positioned forwards of fastening region 86.2õ Furthermore, as clearly
seen
in FIG. 9, third overlay component 814 may completely encircle upper 802 (and
a
foot within upper 802). In an exemplary embodiment, third overlay component
814
is comprised of a first band 817 and a second band 819, which are integrally
joined at top intersection region 815. This arrangement may therefore provide
targeted stretch resistance at forefoot portion 811 that enhances support of
the
foot during activities where forefoot portion 811 may be firmly planted on the
ground.
[0068] Fourth overlay component 816 may be associated with heel
portion 813 of upper 802. In some embodiments, fourth overlay component 816
may provide a heel-counter like overlay portion 825, as well as a strap-like
overlay
portion 827. In combination, overlay portion 8.25 and overlay portion 827 may
help
limit stretching at heel portion 813 and may therefore enhance support of the
heel
within upper 802,
[0069] As seen in FIGS. 10-11, when assembled with upper 802, some
of the overlay components may overlap with one another. For example, third
overlay component 814 is clearly seen to overlap with portions of first
overlay
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component 810 at an overlap region 902. In addition, third overlay component
814
is seen to overlap with portions of second overlay component 812 at an overlap
region 903. Likewise, fourth overlay component 816 is clearly seen to overlap
with
portions of first overlay component 810 at an overlap region 904. This
overlapping
arrangement may help enhance the structural integrity of upper 802, since
portions
of one overlay component may reinforce the support of an overlapping overlay
component. Moreover, by overlapping and joining portions of different overlay
components together, the overlay components may function as a unitary frame
for
supporting the braided structure of upper 802,
[0070] Embodiments
utilizing braided regions having different properties
may include provisions for further reinforcing some regions but not others. In
some embodiments, an article may include an overlay portion that is configured
to
cover a predetermined region of the article.
[0071] FIGS. 12
and 13 illustrate isometric views of an article 1100 that
is configured with overlay portions that cover two specific regions of an
upper 1102.
Specifically, FIG, 12 illustrates an isometric exploded view of article 1100,
while
FIG. 13 illustrates an isometric view including an enlarged cross-sectional
view.
Referring to FIGS. 12 and 13, article 1100 includes upper 1102 and sole system
1110. Upper 1102 is further configured with at least four distinct regions,
including
a first region 1151, a second region 1152, a third region 1153 and a fourth
region
1154. In the exemplary embodiment, first region 1151 is a toe region of upper
1102. Second region 1152 is disposed directly adjacent to, and rearwards of,
first
region 1151. Third region 1153 is disposed adjacent to, and rearwards of,
second
region 1152. Finally, fourth region 1154 extends rearwards of third region
1153.
Moreover, fourth region 1154 is a substantially larger region than the
remaining
regions, and includes the entirety of midfoot portion 1103 and heel portion
1105 of
upper 1102. Thus, first region 1151, second region 1152 and third region 1153
may be characterized as bands of upper 1102 that extend laterally across upper
1102.
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[0072] Each region of upper 1102 may be associated with a particular
material characteristic, such as a braiding density. In the exemplary
embodiment,
first region 1151 and third region 1153 are both associated with a first
braiding
density, while second region 1152 and fourth region 1154 are associated with a
second braiding density. In some embodiments, the first braiding density may
be
greater than the second braiding density. Thus, first region 1151 and third
region
1153 are more tightly braided and may provide regions of increased strength
and
may also resist stretching in some embodiments.
[0073] Article 1100 may be further associated with first overlay portion
1160 and second overlay portion 1162. First overlay portion 1160 may be shaped
to cover first region 1151 of upper 1102. Second overlay portion 1162 may be
shaped to cover third region 1153 of upper 1102. For example, as shown in the
enlarged cross-sectional view of FIG. 13, second overlay portion 1162 may be
disposed over strands 1170 of third region 1153. With this arrangement, first
overlay portion 1160 and second overlay portion 1162 may further reinforce
first
region 1151 and second region 1153, thereby enhancing support and stretch
resistance in these regions.
[0074] The exemplary embodiments are only intended to illustrate some
possible configurations for overlay portions on an upper. It should be
understood
that some other embodiments may include overlay portions configured in a
variety
of different shapes, sizes and locations. Moreover, any number of distinct
overlay
components can be used in alternative embodiments. The number, shape, size
and location of overlay components or overlay portions can be selected to
achieve
desired properties including stretch resistance, enhanced strength, support,
comfort or any other desired properties at any locations on an article of
footwear.
[0075] As discussed in the Braided Upper application, braided uppers
can be configured with a variety of different features and functionality. It
should be
understood that the overlay portions described in this detailed description
may be
utilized with a variety of different embodiments of braided uppers, which may
or
may not include some of the features discussed in the Braided Upper
application.
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As an example, in some embodiments, strands with different material properties
could be braided together, or otherwise associated with one another, to
provide
specific properties at one or more regions of an upper. For example, an upper
may be fabricated from fibers that stretch to a certain degree, as the
wearer's foot
moves through each stride he or she takes, thus increasing the wearer's
comfort.
In that case, high tensile strength, non-stretch fibers may be threaded
through
those specific regions of the footwear that require additional structural
support. As
another example, an upper may be fabricated with a more open braid in some
areas, for example to improve breathability or comfort. In that case,
additional
fibers may be laced through the braid to provide additional support in certain
parts
of those areas, or to provide increased durability for high-impact regions of
the
footwear. An upper having any of these configurations may be further
associated
with one or more overlay portions in order to further control the
characteristics and
functionality of the upper, including support and/or stretch resistance in
various
areas of the upper.
[0076] The upper may also have floating cables, i.e., cables that are
not
braided into the fabric of the upper may be used to relieve the stress on
certain
sections of the upper. The floating cables may be made of a different material
that
is separate from and not attached to the braided structure. The cables may
also
be used as laces to secure the footwear to the foot, or to tighten up certain
parts of
the footwear, as described below. For example, the cables may be anchored at a
first end at the sole of the footwear, and at a second end at an eyelet, for
example.
Such floating cables may also be used to add to the support and stability of
certain
parts of the footwear, such as around the ankle opening. In some embodiments,
overlay portions may be used with braided uppers incorporating floating
cables,
and in some cases the overlay portions may be used to reinforce portions with
cables or portions without cables. In some embodiments, overlay portions could
be used to help anchor ends of the floating cables to the upper.
[0077] The combination of these features, including any of the features
described in the Braided Upper application, in conjunction with the overlay
portions
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described above and shown in the figures may facilitate the creation of uppers
tailored to a particular athletic or recreational activity. Braided uppers
with
combinations of these features can be very light while conforming closely and
comfortably to the wearer's feet. In some embodiments, the fit of the upper
may
be adjusted to provide the specific degree of tension or tightness the wearer
may
prefer.
[0078] FIGS. 14-17 illustrate several steps in an exemplary
process of
forming an article comprised of a braided upper and overlay portions.
Initially, as
shown in FIG. 14, a braided upper 1402 may be formed using any kind of
braiding
process. An exemplary process for forming braided articles is disclosed in the
Braided Upper application, which has been previously discussed. Next, as shown
in FIG. 15, in some embodiments, an opening 1502 may be cut into upper 1402.
This may create a new edge 1504 that bounds opening 1502. Opening 1502 may
be used for insertion of a foot, and may provide a region for a fastener, such
as a
lace.
[0079] In an exemplary embodiment, an overlay portion 1510 may
then
be bonded along edge 1504 (see FIG. 15) of upper 1402, as shown in FIG. 17. In
some embodiments, the bonding may be achieved using a welding process, such
as an ultrasonic welding process. The strands exposed along edge 1504 may
thereby be fused to overlay portion 1510 to finish the ends as well as to
reinforce
and support edge 1504 when the article is fastened. Finally, as shown in FIG.
17,
a lace 1602 may be inserted through eyelets 1610. Additionally, in some
embodiments, a sole system 1620 may be added to the bottom of upper 1402.
[0080] Some embodiments can include provisions to facilitate
the joining
of an upper and a sole system. In some embodiments, an overlay portion may be
provided between an upper and a sole system, thereby facilitating the joining
of
the upper and the sole system.
[0081] FIGS. 18 and 19 illustrate isometric views of an
embodiment in
which an overlay portion may be used to help attach a sole system to an upper.
Referring to FIGS. 18 and 19, an upper 1702 may be associated with an overlay
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component 1720 and an overlay component 1722. In some embodiments, overlay
component 1720 may be associated with an opening 1716 of upper 1702. Overlay
component 1722 may be associated with a lower side 1703 of upper 1702. In
some embodiments, overlay component 1722 may extend over the entirety lower
side 1703, though in other embodiments, overlay component 1722 may only
extend over some portions of lower side 1703. Moreover, in some cases, overlay
component 1722 may partially extend up around a lower periphery 1705 of upper
1702,
[0082] In some embodiments, a sole system 1730 may be associated
with upper 1702. In some embodiments, moreover, overlay component 1722 may
facilitate the bonding or joining of sole system 1730 to upper 1702. For
example,
as clearly seen in the enlarged cross-sectional view in FIG. 19, overlay
component
1722 may be disposed between sole system 1730 and lower side 1703 of upper
1702 to factate the joining sole system 1730 with upper 1702.
[0083] In some embodiments, the material properties of overlay
component 1722 and sole system 1730 can be selected so that overlay
component 1722 and sole system 1730 may be easily bonded using an adhesive
or other process. For example, it is contemplated that in some embodiments;
overlay component 1722 may be made of a thermoplastic urethane (TPU) material,
and sole system 1730 may be made of a similar material or a material that
easily
bonds with TPU. In still other embodiments, however, overlay component 1722
and sole system 1730 can be made of any other materials that can be joined
with
or without a separate adhesive.
[0084] While various embodiments have been described, the description
is intended to be exemplary, rather than limiting and it will be apparent to
those of
ordinary skill in the art that many more embodiments and implementations are
possible that are within the scope of the embodiments. Accordingly, the
embodiments are not to be restricted except in light of the attached claims
and
their equivalents. Also, various modifications and changes may be made within
the scope of the attached claims.
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